IRS Transaxle Rebuild

mcmscott · Posted: Fri Jul 24, 2015 8:56 am Post subject:

That is exactly how I hold third when machining it
_________________
There are no stupid questions, only stupid people,

68 Ghia
67 T-1
65 Notch
02 Mexican beetle
74 Thing
15 Long travel rail
07 Nomad
05 f-250

nsracing · Posted: Fri Jul 24, 2015 12:22 pm Post subject:

Timmy,

'double thin clip' on the 3rd gear?

Why do you think there is a round shiny area on top of that 3rd gear? Smile

You sure you got the right clip on there?

Casting Timmy · Posted: Fri Jul 24, 2015 4:28 pm Post subject:

It's the right clip, just the thinnest version of it. They have multiple thicknesses you can get to get a small or zero clearance. Doing it like this I saw someone reference learning from Scott. I also like it as I feel you get a flatter surface on the gear.

mark tucker · Posted: Sat Jul 25, 2015 9:09 am Post subject:

I use a hard shim between the gear & the clip. more serface aera.

mark tucker · Posted: Sat Jul 25, 2015 9:27 am Post subject:

just wanted to warn him not to mar the bearing race finish.
I'm making a jig/tool like vw has for the diff preload. almost done.it should make it easy. I had to make a modification to the orignal one i made 3 days ago as I did it on a oe cover and wouldent work on a aftermarket cover Shocked

the fins got in the way Rolling Eyes

it's always something. and tomany migrains to think clear enough to work on trans currently. at this rate it will never be finished before Im dead.
my new snappon rotating torque wrench arived today!!!!I wonder how to use it Shocked

can I put it in the crank bolt to see how much torque my motor puts out Question

.........dang that thing flys far Shocked

Casting Timmy · Posted: Sat Jul 25, 2015 6:23 pm Post subject:

Early gear on late main shaft and you are able to pop off the brazed synchro cones on beetle gears.

http://www.thesamba.com/vw/forum/viewtopic.php?p=5678374

gears · Posted: Sun Jul 26, 2015 11:07 pm Post subject:

Those brazed-on synchro cones will only fit a gear specifically made for them.
_________________
aka Pablo, Geary
9.36 @ 146 in '86 Hot & Sticky
'90 Syncro Westy SVX
'87 Syncro GL 2.5
https://guardtransaxle.com

Casting Timmy · Posted: Mon Jul 27, 2015 4:31 am Post subject:

I was wondering that a little as I looked at it last night. I didn't think the fine toothed gears were worth much, why do people press th off? Couldn't you buy a new set for about nothing?

mark tucker · Posted: Mon Jul 27, 2015 9:48 am Post subject:

have you priced them??

Bruce · Posted: Mon Jul 27, 2015 1:34 pm Post subject:

Casting Timmy · Posted: Tue Jul 28, 2015 4:19 am Post subject:

I have the 93 4ths....only $15 off Weddle for the set. I guess with the 1.32 third only $24 this isn't a bad build for money either. I already had the fourth and bought the 1.32 long ago with some other stuff.

Casting Timmy · Posted: Fri Jul 31, 2015 4:13 pm Post subject:

I got out to the garage again, started the process of welding my third gear. I should have ground it out more, but I think it will be fine in the end just more sanding.

I should have ground out more.

Image may have been reduced in size. Click image to view fullscreen.

I like aluminum for supporting at times as the steel is stronger.

First two welds

Second set of welds added

I might do one more weld in the one side before sanding it down.

mark tucker · Posted: Fri Jul 31, 2015 6:58 pm Post subject:

funny mine were tig welded and no blueing.wonder why?

Casting Timmy · Posted: Sat Aug 01, 2015 5:01 am Post subject:

I have a blue car so it works out good....first time doing this and could have been better but I'm happy with the results so far as it will definitely be usable.

The synchro spins freely on it and it spins great on the bearing, so all in all I think it went well. Probably a lot better examples out there, but I hope this will get the job done.

I should be able to make some progress again later this week as I get my 091 clips in from Weddle. I'll try and get some other things done on my lunch breaks before then, especially getting the case ready for cleaning.

mark tucker · Posted: Sat Aug 01, 2015 9:14 am Post subject:

they should do fine, I would however in the future use something to protect the inner race in the gear and also posiably the teeth from any spatter dingleballs.

Casting Timmy · Posted: Sat Aug 01, 2015 10:06 am Post subject:

Trust me on that one. I did have to clean the inside a little. But you would never know it now, took my time and it cleaned up really nice.

mark tucker · Posted: Sun Aug 02, 2015 2:47 am Post subject:

if they touched the bearing race portion I would hone it on a rod hone to be sure.

gears · Posted: Sun Aug 02, 2015 11:43 am Post subject:

Over-honed bores allow helical gears to cock, placing all load at one end of the teeth. If the gear feels notchy on the bearing ON THE SHAFT .. that's when a light honing is called for. If too much is taken out, you're forced to use loose needles to keep the idler square under load. Loose needles are fine in drag cars, but add undesirable friction in street cars, IMO. Distortion can be avoided during the welding process.
_________________
aka Pablo, Geary
9.36 @ 146 in '86 Hot & Sticky
'90 Syncro Westy SVX
'87 Syncro GL 2.5
https://guardtransaxle.com

modok · Posted: Sun Aug 02, 2015 11:57 am Post subject:

That's nothin! I've seen them weld 1/3 of the surface!
distortion won't be a big deal.
Steel goes blue at 500 degrees so YEAH it's gonna have a blue zone. because you can't weld steel cold. Lemme take a wire brush and remove the blue before you let "the experts" examine it. LOL

Bruce · Posted: Sun Aug 02, 2015 1:13 pm Post subject:


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